Aerosol Spray Texture Apparatus for a Particulate Containing Material

ABSTRACT

An outlet system for a hardenable acoustic texture material aerosol dispensing system. The outlet system comprises a discharge assembly movably supported such that a first return member automatically returns the discharge assembly to a first position when the discharge assembly is displaced a predetermined distance from the first position.

RELATED APPLICATIONS

This application (Attorney's Ref. No. P216936) is a continuation of U.S.application Ser. No. 12/360,833, filed Jan. 27, 2009.

U.S. application Ser. No. 12/360,833 is a divisional of U.S. applicationSer. No. 10/991,611, filed Nov. 18, 2004, now U.S. Pat. No. 7,481,338,which issued Jan. 27, 2009.

U.S. application Ser. No. 10/991,611 is a continuation of U.S.application Ser. No. 10/691,897, filed Oct. 22, 2003, now U.S. Pat. No.7,014,073, which issued Mar. 21, 2006.

U.S. application Ser. No. 10/691,897 is a continuation of U.S.application Ser. No. 10/047,041, filed Jan. 14, 2002, now U.S. Pat. No.6,641,005, which issued Nov. 4, 2003.

U.S. application Ser. No. 10/047,041 is a continuation of U.S.application Ser. No. 09/703,409, filed Oct. 31, 2000, now U.S. Pat. No.6,352,184, which issued Mar. 5, 2002.

U.S. application Ser. No. 09/703,409 is a continuation of U.S.application Ser. No. 09/203,547, filed Dec. 1, 1998, now U.S. Pat. No.6,152,335, which issued Nov. 28, 2000.

U.S. application Ser. No. 09/203,547 is a continuation-in-part of U.S.application Ser. No. 08/950,202, filed Oct. 14, 1997, now abandoned.

The contents of all related applications listed above are incorporatedherein by reference.

TECHNICAL FIELD

The present invention relates to a texture spraying apparatus fordischarging a texture material onto a surface, and more particularly toan aerosol spray texture apparatus particularly adapted to discharge atexture material having particulate matter contained therein.

BACKGROUND

Buildings are commonly comprised of a frame to which a roof, exteriorwalls, and interior walls and ceilings are attached. The interior wallsand ceilings are commonly formed using sheets of drywall material thatare attached to frame, usually by screws. Gaps are normally formedbetween adjacent sheets of drywall material. In addition, the screws arecountersunk slightly, and the screw heads are visible.

To hide the gaps and screw heads, they are covered with tape and/ordrywall compound and sanded so that the interior surfaces (wall andceiling) are smooth and continuous. The interior surfaces are thenprimed for further finishing.

After the priming step, a texture material is often applied to interiorsurfaces before painting. The texture material forms a bumpy, irregularsurface that is aesthetically pleasing. The textured interior surfacealso helps to hide irregularities in the interior surface.

Some interior surfaces, especially ceilings, are covered with a specialtype of texture material referred to as acoustic texture material.Acoustic texture material contains particulate material that adheres tothe interior surface. The purpose of the particulate material is partlyaesthetic and partly functional. The particles absorb rather thanreflect sound and thus can reduce echo in a room. The term “acoustic”texture material is used because of the sound absorptive property ofthis type of texture material.

When repairs are made to interior walls and ceilings, the texturematerial often must be reapplied. The newly applied texture materialshould match the original texture material.

A number of products are available that allow the application of texturematerial in small quantities for the purpose of matching existingtexture material. In addition to hopper based dispensing systems,texture material may be applied in small quantities using aerosolsystems. With conventional texture material that does not includeparticles, a variety of oil and water based texture materials in aerosoldispensing systems are available.

Acoustic texture materials pose problems that have heretofore limitedthe acceptance of aerosol dispensing systems. In particular, mostacoustic texture materials contain polystyrene chips that dissolve incommercially available aerosol propellant materials. Thus, conventionalaerosol propellant materials are not available for use with acoustictexture materials.

The Applicants have sold since approximately 1995 a product that employscompressed inert gas, such as air or nitrogen, as the propellant. Thecompressed gas does not interact with the particles in the acoustictexture material. The compressed air resides in the upper portion of theaerosol container and forces the acoustic texture material out of thecontainer through a dip tube that extends to the bottom of thecontainer.

While commercially viable, the use of compressed inert gas to dispenseacoustic texture material from an aerosol container assembly presentsseveral problems. First, if the aerosol system is operated whileinverted, the compressed inert gas escapes and the system becomesinoperative. Second, the compressed inert gas can force all of theacoustic texture material out of the aerosol container in a matter ofseconds. An inexperienced user can thus inadvertently and ineffectivelyempty the entire container of acoustic texture material.

The Applicants are also aware of an aerosol product that sprays a foammaterial instead of a true acoustic texture material. The foam materialdoes not contain particulate material, and thus the resulting textureformed does not match an existing coat of true acoustic texturematerial.

The need thus exists for a system for dispensing acoustic texturematerial that provides the convenience of an aerosol dispensing system,employs true acoustic texture material, and is easily used byinexperienced users.

RELATED ART

There are in the prior art various devices to spray a texture materialonto a wall surface or a ceiling. Depending upon the nature of thecomposition and other factors, the material that is sprayed onto thesurface as a coating can have varying degrees of “roughness”.

In some instances, the somewhat roughened texture is achieved byutilizing a textured composition that forms into droplets when it isdispensed, with the material then hardening with these dropletsproviding the textured surface. In other instances, solid particulatematerial is mixed with the liquid texture material so that with theparticulate material being deposited with the hardenable liquid materialon the wall surface, these particles provide the textured surface.However, such prior art aerosol spray texture devices have not beenproperly adapted to deliver a texture having particulate matter thereinto provide the rougher texture.

In particular, the Applicants are aware of prior art spray texturedevices using an aerosol container which contains the texture materialmixed with a propellant under pressure and from which the texturedmaterial is discharged onto a surface. Such aerosol dispensers arecommonly used when there is a relatively small surface area to becovered with the spray texture material. Two such spray texture devicesare disclosed in U.S. Pat. No. 5,037,011, issued Aug. 6, 1991, and morerecently U.S. Pat. No. 5,188,263, issued Feb. 23, 1993 with John R.Woods being named inventor of both of these patents.

Additionally, the Assignee of the present invention has sinceapproximately 1983 manufactured and sold manually operated devices forapplying spray texture material onto walls and ceilings. These spraytexture devices are described in one or more of the following U.S. Pat.Nos. 4,411,387; 4,955,545; 5,069,390; 5,188,295.

Basically, these spray texture devices comprised a hopper containinghardenable material, a manually operated pump, and a nozzle. By pointingthe device at the area being patched and operating the manual pump, thehardenable material and pressurized air generated by the pump were mixedin the nozzle and subsequently sprayed onto the area being patched.

When applied to a ceiling, the hardenable material employed by theseprior art spray texture devices basically comprised a mixture of thefollowing ingredients:

-   -   a. water to form a base substance and a carrier for the        remaining ingredients;    -   b. a filler substance comprising clay, mica, and/or calcium        carbonate;    -   c. an adhesive binder comprising natural and/or synthetic        polymers; and    -   d. an aggregate comprising polystyrene particles.

The filler, adhesive binder, and aggregate are commercially availablefrom Hamilton Materials, Inc. under the tradename PurTex.

The hardenable material employed by these prior art spray texturedevices further comprised one or more of the following additionalingredients, depending upon the circumstances: thickeners, surfactants,defoamers, antimicrobial materials, and pigments.

SUMMARY

The present invention is a dispensing system that allows apredetermined, metered quantity of material to be dispensed from anaerosol container. The dispensing system is particularly adapted todispense acoustic texture material including particles of polystyrenemixed throughout.

The present invention comprises a container system for containing thetexture material and a compressed inert gas as a propellant, a valveassembly operable in an open and close configuration for allowing orpreventing fluid flow from the container assembly, an outlet assemblyfor dispersing the texture material dispensed thereby, and a meteringassembly that interacts either with the valve assembly or the outletassembly to allow the user to control the amount of texture materialdispensed.

The metering system may be as simple as a collar that limits the outletassembly to limit the flow rate of the texture material exiting thesystem and thus provide the user with more control over the amount oftexture material dispensed.

A more complex system requires the user to depress an actuator memberfully at which point the metering assembly will release the valveassembly and cause the valve assembly to return to its closed positionwithout any interaction by the user.

An even more complex system may require the user to press an actuatormember to energize the system. After the actuator member has beendepressed by a predetermined amount, the valve is triggered open andthen released to close without further input from the user. In thiscase, the user has no control over the amount of texture materialdispensed and thus cannot inadvertently dispense the entire contents ofthe can.

The metering assembly can be mounted within the container assembly orabove the container assembly around the valve stem. Another type ofmetering assembly is located completely outside of the container andsimply acts on a conventional valve assembly.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a highly schematic view depicting the major components of anaerosol dispenser for acoustic texture material constructed inaccordance with, and embodying, the principles of the present invention.

FIG. 1A is an isometric view showing a first embodiment the presentinvention being held in a person's hand in a manner to operate theapparatus to dispense the textured material therefrom;

FIG. 2 is a longitudinal sectional view showing the valve assembly ofthe first embodiment and a small portion of the aerosol container, withthe valve assembly in its closed position;

FIG. 3 is a view similar to FIG. 2, but showing the valve assembly inits open position;

FIG. 4 is a view similar to FIG. 3, but showing a second embodiment ofthe present invention, where the valve assembly has a differentarrangement for the vent openings of the valve assembly; and

FIG. 5 is a drawing similar to FIG. 3, but drawn to an enlarged scale,and giving various dimensions which in a prototype have been proved tobe suitable in the present invention.

FIG. 6 is a longitudinal sectional view of a third embodiment of thepresent invention;

FIG. 7 is an isometric view of an upper portion of the valve assembly ofthe third embodiment;

FIG. 8 is a longitudinal sectional view of that portion of the valveassembly illustrated in FIG. 7;

FIG. 9 is a longitudinal sectional view of the lower and middle portionof the valve assembly of the third embodiment of FIG. 6, with the valvein the closed position;

FIG. 10 is a view similar to FIG. 9, but showing the valve in the openposition;

FIG. 11 is a longitudinal sectional view, similar to FIG. 6, of a fourthembodiment of the present invention;

FIG. 12 is a longitudinal sectional view of the lower part of the valveassembly of the fourth embodiment of FIG. 11;

FIG. 13 is a longitudinal sectional view of a fifth embodiment of thepresent invention;

FIG. 14 is a longitudinal sectional view of a sixth embodiment of thepresent invention;

FIG. 15 is an enlarged longitudinal section view of a portion of theseventh embodiment of FIG. 16, with a broken line circle showing thatportion of FIG. 16 enlarged as FIG. 15;

FIG. 16 is a longitudinal sectional view of a seventh embodiment of thepresent invention;

FIG. 17 is a longitudinal sectional view of an eighth embodiment of thepresent invention;

FIG. 18 is a top plan view of an actuator assembly that may be used withthe present invention;

FIG. 19 is a longitudinal section view taken along lines 19-19 of FIG.18;

FIG. 20 is a top plan view of another actuator assembly that may be usedwith the present invention;

FIG. 21 is a front elevational view of the actuator assembly of FIG. 20;

FIG. 22 is a longitudinal section view taken along lines 22-22 in FIG.21;

FIG. 23 is a top plan view of yet another actuator assembly that may beused with the present invention;

FIG. 24 is a longitudinal section view taken along lines 24-24 of FIG.23;

FIG. 25 is a top plan view of still another actuator assembly that maybe used with the present invention;

FIG. 26 is a top plan view of another actuator assembly that may be usedwith the present invention;

FIG. 27 is a longitudinal section view taken along lines 27-27 in FIG.26;

FIG. 28 is a top plan view of yet another actuator assembly that may beused with the present invention;

FIG. 29 is a longitudinal section view taken along lines 29-29 in FIG.28;

FIG. 30 is a top plan view of another actuator assembly that may be usedwith the present invention;

FIG. 31 is a longitudinal section view taken along lines 31-31 in FIG.30.

FIGS. 32A-D depict a ninth embodiment of a dispensing system of thepresent invention having a metering assembly to facilitate applicationof a predetermined quantity of acoustic texture material;

FIG. 33A-D are section views depicting a tenth embodiment of adispensing system of the present invention;

FIGS. 34A-G are section views of an eleventh embodiment of a dispensingsystem of the present invention;

FIGS. 35A-G are section views taken along a different plane andcorresponding to FIGS. 34A-G;

FIG. 36 is a section view taken along lines 36-36 in FIG. 34A;

FIG. 37 is a section view taken along lines 37-37 in FIG. 34A;

FIG. 38 is a section view of a twelfth embodiment of the presentinvention;

FIG. 39 is a partial section view of a dispensing system of a thirteenthembodiment of the present invention;

FIG. 40 is a section view of a dispensing system of a fourteenthembodiment of the present invention;

FIG. 41 is a section view taken along lines 41-41 in FIG. 40;

FIG. 42 is a section view taken along lines 42-42 in FIG. 40;

FIG. 43 is a section view of a fifteenth embodiment of a dispensingsystem of the present invention;

FIG. 44 is a side elevational view of the dispensing system of FIG. 43;

FIG. 45 is a section view taken along lines 45-45 in FIG. 43;

FIG. 46 is a side elevational view of a dispensing system of thesixteenth embodiment of the present invention;

FIG. 47 is a section view of the dispensing system depicted in FIG. 46;and

FIG. 48 is a partial section view taken along lines 48-48 in FIG. 46.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

As schematically depicted in FIG. 1, the present invention is an aerosoldispensing system 1 comprising a number of individual components thatare designed to work together in a manner that allows acoustic texturematerial to be applied to a surface to be coated.

The aerosol dispensing system 1 comprises a fluid portion 2 and amechanical portion 3. The fluid portion 2 comprises a hardenableacoustic texture material 4 containing particles 5 and a propellantmaterial 6. The mechanical portion 3 comprises a container assembly 7, avalve assembly 8, and an actuator assembly 9.

Each of these individual components will be described in general below,and following that will be described a number of specific embodiments ofthe present invention that illustrate how these components work togetherto obtain an aerosol system or method for dispensing acoustic texturematerial.

I. Fluid Portion

The fluid portion 1 of the dispensing system and method of the presentinvention comprises the material 4 to be dispensed, hereinafter theacoustic texture material or hardenable material, and the propellantmaterial 6.

Referring initially to the hardenable acoustic texture material 4, theApplicants determined that, in the context of applying ceiling texturematerial to an interior surface such as a ceiling, the composition ofthe hardenable material was limited by the result desired. Inparticular, the Applicants determined that the hardenable acoustictexture material 4 must, at a minimum, include polystyrene chips orbeads as the particles 5 in order to obtain a textured surface thatwould satisfactorily match the surrounding original textured surface.

In general, the particles may be polystyrene, cork or other types offoam material, such as 88% polyethylene and 12% ethylene vinyl acetate,natural or synthetic rubber, elastomer, etc.

When particulate material comprising particles other than expandedpolystyrene were used, however, either the spray texture material wouldnot spray properly (i.e., the particles would bounce off the ceiling),the spray texture material would not match the original texture on theceiling, and/or it would clog or bridge in the pick-up opening in thetube.

Accordingly, the Applicants determined that, in order to develop anaerosol product that would obtain acceptable results for patching atextured ceiling, commercially available ceiling spray texture materialas has long been used by prior art non-aerosol spray texture devices ispreferably used as part of the hardenable material.

The hardenable material 4 may include:

(a) water as a base and carrier;

(b) PurTex, a commercially available acoustical ceiling texturematerial; and

(c) Foammaster 1119A, a commercially available defoamer.

The PurTex product basically comprises a calcium carbonated, mica,and/or clay as filler material, natural and/or synthetic binder, apreservative, and polystyrene chopped beads.

In addition to the ingredients recited above, the hardenable materialmay also comprise the following ingredients:

(a) a thickener that controls the film integrity of the composition;

(b) a surfactant;

(c) an antimicrobial component; and

(d) a pigment compound (often a whitener).

Of the foregoing ingredients, the commercially available ceiling texturematerial could not be eliminated or altered without materially alteringthe appearance of the texture pattern formed thereby. This texturematerial is a mixture that comprises a carrier fluid component and aparticulate material having particles which are mixed throughout thecarrier fluid. The particulate material is made from an expandedpolystyrene having a predetermined particle size. Commonly, theparticles of the mixture have a variety of sizes to provide a texturesurface having different particle sizes.

One preferred formulation of the texture mixture is comprised of thefollowing ingredients:

-   -   a. a thickener that controls the film integrity of the        composition;    -   b. a surfactant;    -   c. a defoamer to facilitate the processing and minimize bubbles        when spraying;    -   d. an antimicrobial component;    -   e. a pigment component (often a whitener);    -   f. a commercially available ceiling texture material with the        particles distributed therein.    -   g. water.

The commercially available ceiling texture material basically comprisescalcium carbonate, mica, and/or clay as a filler, a synthetic or naturalbinder, a preservative, and polystyrene chopped beads.

Attached hereto in Appendix A are Tables A-F. These tables contain theformulas employed by the Applicants to obtain the hardenable materialdispensed by the present invention. Currently, the formula contained inTable F describes the preferred commercial form of the hardenablematerial dispensed by the present invention.

In the attached tables, trade names are used to identify certaincommercially available ingredients. The ingredient PureTex was describedabove. The purpose of each of the remaining ingredients will bedescribed below: PMO 30 is a preservative; BENTONE LT is a thickener;NUOSEPT 95 is a preservative; KTPP is a surfactant; COLLOIDS 648 is adefoamer; BUSAN 11M1 is a filler, preservative, antifoamant, dispersant;TITAN 2101 is a white pigment, MINUGEL 400 is a thickener; BENTONE EW isa thickener; and FOAMASTER 1119A is a defoamer.

The other major component of the fluid portion 2 is the propellantmaterial 6. The propellant employed may be a compressed inert gas suchas air or nitrogen that is separate from and acts on the hardenablematerial. The propellant may also be comprised of 50% propane and 50%isobutane, but the particles, or aggregate, cannot be formed ofpolystyrene in this case.

As discussed above, in the preferred case the hardenable acoustictexture material 4 should, for aesthetic purposes, include thepolystyrene chips or beads 5. Accordingly, in the preferred case thepropellant material 6 is preferably a compressed inert gas. Appropriateinert gasses include air, nitrogen, or a combination thereof. Thecompressed inert gas will not adversely affect the hardenable material 4and, in particular, will not dissolve or otherwise cause thedeterioration of the polystyrene chips or beads 5 contained therein.

II. Mechanical Portion

A shown in FIG. 1, the valve assembly 8 is mounted within the containerassembly 7, and the actuator assembly 9 is mounted on the valve assembly8. The valve assembly 7 is normally in a closed configuration in whichfluid, namely the hardenable material 4, is prevented from exiting thecontainer assembly 7. The operator depresses the actuator assembly 9 toplace the valve assembly 7 into its open configuration. When the valveassembly 7 is in its open configuration, an exit passageway is createdthat allows fluid to flow out of the container assembly 7 through theactuator assembly 9.

The container assembly 7 is generally conventional, except that it maybe modified slightly as necessary to mount the valve assembly 8 andactuator assembly 9.

The valve assembly 8 and actuator assembly 9 are unique to the presentinvention and will be described as necessary below in the discussion ofthe preferred embodiments.

III. First Embodiment

In FIG. 1A, it can be seen that the apparatus 10 of the presentinvention comprises an aerosol container 12 defining a main pressurechamber 13, and having at its upper end 14 a valve assembly 16. Thecontainer 12 has an overall cylindrical configuration, comprising acylindrical sidewall 17, a top wall 18 (either integral with thesidewall 17 or made separately), and a bottom wall (not shown for easeof illustration). The valve assembly 16 is mounted at the center of thetop wall 18.

The valve assembly 16 comprises a valve housing 20 mounted to the topcontainer wall 18, and a valve stem or element 22 positioned within thehousing 20 for movement between the closed position of FIG. 2 to theopen position of FIG. 3. Fixedly attached to the upper end of the valveelement 22 is a manually operable actuating and discharge portion 24,comprising a mounting portion 26, a cross bar 28, a discharge nozzle 30extending upwardly from the mounting portion of 26, and a pair ofpositioning legs 32 extending downwardly from the mounting portion 26and positioned diametrically opposite from one another.

The valve housing 20 comprises an annular mounting collar 34 having anouter circumferential mounting lip 36, having in cross section asemi-circular configuration so as to provide a downwardly facingcircular recess to be attached to a matching circular lip formed in thetop wall 18 of the container 12. The collar 34 extends downwardly ashort distance from the lip 36 as a side wall 38 and has a lowerinwardly extending annular wall portion 40.

The valve housing 20 also comprises a lower cylindrical housing portion42 which defines a lower valve chamber 44 located at the lower end ofthe valve stem 22, and a lower wall 45.

Extending downwardly from the housing portion 42 is a lower intake tube46. It will be noted that there is formed in the lower wall 45 of thehousing portion 42 a plurality of vent openings 47 positioned radiallyoutwardly of a tube 46 and leading from the main chamber 13 in thecontainer 12 into the lower valve chamber 44. The function of these ventopenings 47 will be discussed later herein in connection with theoverall operation of the apparatus 10 of the present invention.

The tube 46 has an upper end 48 connecting to the center part of a lowerwall 45 of the housing portion 42 and a lower end 52 that is positionedat the lower end of the container 12. This tube 46 defines a verticalpassageway 54 extending from the lower intake opening 56 of the tube 46upwardly to an upper outlet opening 58 leading into the lower valvechamber 44. The lower housing portion 42 has a downwardly extending stub60 that fits within the upper end of the tube 46 and defines the upperopening 58.

There is an intermediate flexible fitting 62 which is operably connectedand positioned between the valve housing 20 and the valve element 22. Ascan be seen in FIG. 5, this fitting 22 comprises an upper tubularportion 64, a lower seal portion 66 and a middle connecting portion 68interconnecting the upper tubular portion 64 and lower seal portion 66.

This intermediate fitting 62 can be made of a moderately flexible rubberor synthetic rubber material, and it performs a number of functions.First, the upper tubular portion 64 serves as a resilient spring memberwhich urges the valve element 22 toward its upper closed position ofFIG. 2. The lower seal portion 66, as its name implies, serves to createa seal between the valve element 22 and the valve housing 20 in theclosed position of FIG. 2. The connecting portion 68 functions toposition the valve element 22 relative to the housing 20, and alsointerconnects portion 64 and 66.

Before describing this flexible fitting 62 in more detail, there will bea further description of the valve stem or element 22. The valve element22 has an overall cylindrical configuration and defines a centralvertical discharge passageway 70 that leads to the nozzle 30 thatdefines the upper portion 72 of the passageway 70. The upper part of thevalve element 22 has exterior threads 73 which interconnect with theinterior threads formed in the mounting portion 26 of the actuating anddischarge portion 24. The lower middle portion 74 of the valve elementhas the same cylindrical configuration as the upper portion, with asmooth outer surface, and the upper tubular portion 64 of the flexiblefitting 62, in the closed position of FIG. 2, fits snugly around theouter surface of this lower cylindrical portion 74.

At the lower end of the valve element 22 there is fixedly attachedthereto a circular horizontal closure disc or plate 76 that closes thelower end of the discharge passageway 70. The upper perimeter surface ofthis closure planar disc 76 fits against a lower circumferential sealsurface 78 of the seal portion 66 of the fitting 62. There is aplurality of side openings 80 formed in the side wall at the lower endof the valve element 22, at a location immediately above the lowerclosure plate 76. In the preferred configuration shown herein, there aretwo such openings 80, positioned diametrically opposed to one another.

To describe further the intermediate flexible fitting 62, the uppercircular edge of the tubular portion 64 bears against an annularprotrusion 82 of the valve element 22. The lower end of the tubularportion 64 has a moderately expanded circumferential lip 84 that extendsover and engages the inner edge of the lower housing wall 40 thatdefines an opening that receives the flexible fitting 62 and the valveelement 22. Thus, it can be seen from observing FIGS. 2, 3 and 5 that asthe actuating and discharge portion 24 (fixedly connected to the valveelement 22) is pushed downwardly, the tubular portion 64 of the flexiblefitting 62 is compressed axially (see FIGS. 3 and 5) so as to urge thevalve element 22 with the actuating and discharge portion upwardly tothe position of FIG. 2. At the same time, the connecting portion 68 ofthe flexible fitting 62 continues to position the valve element 22centrally within the collar 34 of the valve housing 20.

With regard to the seal portion 66 of the flexible fitting 62, this hasin cross section a generally frusto conical configuration, with an innercylindrical wall that fits around the lower part of the valve element22. The upper circumferential surface 86 of the seal portion 66 fitsagainst the lower surface of the inner lower wall 40 of the housingcollar 34. In the position of FIG. 2, the aforementioned seal surface 78is in sealing engagement with the upper surface of the closure plate 76of the valve element 22 so as to form a seal so that the texturematerial that is positioned in the valve chamber 44 is sealed from thedischarge passageway 70 in the valve element 22.

However, when the actuating and discharge portion 24 with the valveelement 22 is depressed to the position of FIGS. 3 and 5, it can be seenthat the lower closure plate 76 moves away from the seal surface 78 ofthe seal portion 66 to open the two intake openings 80 at the bottom ofthe valve element 22 so that the texture material in the valve chamber44 is able to move through the openings 80 upwardly through thedischarge passageway 70 and out the upper nozzle portion 72 of thedischarge passageway 70 to pass outwardly therefrom in a spray patternagainst a wall or ceiling surface or the like.

The texture material within the container 12 is a mixture that comprisesa carrier fluid component and a particulate material having particleswhich are mixed throughout the carrier fluid. The mixture is containedwithin the container 12 at a predetermined pressure level which is aboveambient pressure. At this predetermined pressure level a propellantportion of the carrier fluid remains liquid. Normally, there will be gasin the form of vaporized propellant in the upper portion of thecontainer 12 in pressure equilibrium with the liquid phase. However,when the pressure is reduced to a predetermined lower level, thispropellant component vaporizes.

The particulate material is made from a polystyrene material having apredetermined maximum particle size (e.g. an eighth of an inch), witheach particle being compressible to a smaller particle size dimension.Commonly, the particles of the mixture will have a variety of sizes, toprovide a varying texture surface. Other compressible materials, such ascork, that are compatible with the fluid components could be used.

To describe the operation of the present invention, the apparatus 10 isprovided to the end user with the pressurized texture material mixturecontained within the container 12, and with the particulate materialdistributed throughout the liquid component. The actuating and dischargeportion 24 remains in the closed position of FIG. 2, where the valveelement 22 is in the closed position. When it is desired to use thespray texture apparatus 10, the apparatus 10 is grasped in a person'shand as indicated in FIG. 1A, with two of the person's fingers engagingthe opposite sides of the cross bar 28 to depress the cross bar 28 so asto move the valve element 22 downwardly, against the urging of thetubular portion 64 of the intermediate flexible fitting 62 so as to openthe intake openings 80 of the valve element 22. Obviously, other typesof handles and triggering mechanisms could be used.

With the valve element 22 in the open position of FIG. 3 or 5, it can beseen that the lower valve chamber 44 becomes exposed to ambient pressurethrough the valve element openings 80. When this occurs, the pressurizedmaterial in the main chamber 13 forces the texture material upwardlythrough the tube 46 into the valve chamber 44, with the material flowingfrom this chamber 44 into the openings 80 and thence out the dischargepassageway 70. At the same time, the vaporized propellant portion of thefluid component of the texture material passes upwardly through the ventopenings 47 into the valve chamber 44 and mixes and/or atomizes. Thisincreases the percentage of the gaseous component of the carrier fluidthat is passing into and through the valve chamber 44 and out thepassageway 70.

It has been found that the particular arrangement of the presentinvention functions to reliably pass the particles in the mixturethrough the intake openings 80 to be discharged out the passageway 70.In addition to the propellant gas passing upwardly through the vents 47,the fluid component of the mixture is able to have at least thevaporizable portion thereof pass upwardly through the tube 46 into thechamber 44, with this component vaporizing at least partially to formgaseous bubbles in the texture mixture. Within the broader scope of thepresent invention, a propellant in gaseous form or dissolved in a mediumat higher pressure could be utilized. By empirical testing, it isbelieved that the vaporizable portion or propellant serves at least twofunctions. First, it adds gas to the mixture to some extent so that asit passes from the discharge nozzle opening portion 72, it is in adesired spray pattern to be distributed on the wall or ceiling surface.Further, even though the particles in the mixture are close to the samesize as the diameters of the openings 80, these particles pass reliablythrough these openings 80 and outwardly through the passageway 70 andthe nozzle end opening 72. It is surmised that the action of thevaporizable fluid component or propellant being transformed at leastpartially into the gaseous state or as expanded gas cause a certainturbulence and localized pressure variations to jostle or move or forceany particles loose that may temporarily be caught in the openings 80,or possibly in other parts of the valve chamber 44.

IV. Second Embodiment

A second embodiment of the present invention is shown in FIG. 4. This issubstantially the same as the first embodiment, except that the ventopenings (designated 47 a) are positioned in the sidewall of the housing42 a so that these direct flow laterally into the chamber 44 a at thelocation of the intake openings 80 a. It is surmised that this locationof the vent openings 47 a are able to be oriented to effect a tangentialswirling pattern, or oriented more radially to provide a more directforce, in the vicinity of the openings 80 a to enhance proper movementof the particles.

FIG. 5 is an enlarged view giving in inches the dimensions of aprototype built in accordance with the teachings of the presentinvention, and also to show the components more clearly. It is to berecognized, of course, that these dimensions could be increased ordecreased within certain limits (e.g. ten percent, twenty percent, orpossibly as high as fifty percent or higher, and in some instanceschanged to provide different proportional relationships in thesedimensions) to obtain certain design objectives. Further, the openings80 could be made moderately larger than the maximum dimension of theparticles, or in some instances even smaller than the particledimension, if the particles are sufficiently compressible.

V. Third Embodiment

FIG. 6 illustrates at 110 of the third embodiment of the presentinvention which is particularly adapted to apply an acoustic texturematerial to the surface of a ceiling. This apparatus 110 comprises acontainer 112 and a discharge assembly 114. The container 112 defines achamber 116 having a texture material containing portion 118 and apropellant containing portion 120. In this third embodiment, the texturematerial containing portion 118 is located in the bottom part of thechamber 116 since the apparatus 110 is normally operated in a verticallyaligned position so that the texture material 122 is positioned bygravity in the lower part of the chamber 116. The propellant containingportion 120 is in the upper part of the chamber 116, and the propellant124 is a gaseous substance which is substantially inert, such asnitrogen or atmospheric air, relative to the texture material 122. Thereis a pressure interface 126 between the upper surface 28 of the texturematerial 122 and the gaseous propellant 124 that is immediately above,with the propellant 124 being (in this third embodiment) in directcontact with the texture material 122.

The container 112 comprises a cylindrical side wall 130, having an upperfrusto-conical wall section 132, and a bottom wall 134. The dischargeassembly 114 comprises an infeed section 136 and a valve section 138.

The infeed section 136 comprises a feed tube 140 having a lower open end142 positioned adjacent to and just above the bottom wall 134, and anupper end 144 which fits within a downwardly extending stub 146 that ispart of an entry chamber housing 148 that defines an entry chamber 150.To describe briefly the function of this infeed section 136, inoperation the texture material 122 is forced by pressure from thepropellant 124 to flow into the lower open end 142 of the tube 140 andinto the entry chamber 150. From this chamber 150, the texture materialflows into the valve section 138.

The valve section 138 comprises a mounting collar 152 (sometimesreferred to as a “cup”), a flexible valve seal and mounting member 154,a valve stem 156, a valve handle portion 158, a positioning spring 159,and an end nozzle section 160.

With reference to FIGS. 9 and 10, the valve mounting collar 152 has aperimeter portion 162 which extends upwardly from the collar side wall163 to curve upwardly and outwardly and then downwardly in approximatelya 180° curve. This perimeter portion 162 is positioned over acircumferential lip 164 that is formed from an inner circumferentialedge of the upper wall 132 and extends in a circle around the insideedge of the frusto-conical upper wall 132. This lip 164 at its inneredge is curved (as seen in cross section) upwardly, outwardly and thendownwardly in a curved configuration so as to fit within the curvedperimeter portion 162 of the mounting collar 152.

A significant feature of the present invention is the manner in whichthis mounting collar 152 forms a seal with the upper container wall 132and also forms a seal with the aforementioned entry chamber housing 148.More particularly, the entry chamber housing 148 comprises a bottom wall166 and a cylindrical side wall 168. The walls 166 and 168 are madeintegrally of a semi-rigid plastic material which is able to yieldmoderately.

As can be seen in FIG. 9, the upper edge 170 of the side wall 168 hasits thickness dimension reduced to a very small thickness so as to bereasonably flexible. Then the upper edge portion is formed in a curve170 that extends upwardly and inwardly, and then outwardly in a somewhatdownward curve, this curved portion being indicated at 174, so that thisupper curved portion 174 of the chamber member side wall 168 fits snuglybetween the collar perimeter portion 162 of the collar 152 and thecircular lip 164 of the upper container wall 132.

In addition, by initially forming the edge portion 174 of quite thinmaterial (which then can be formed in a circular curve), stresses thatmight be created in thus attaching the upper edge portion 174 to thecontainer lip 164 are not transmitted into the side wall 168 of theentry chamber housing 148.

This connection of the perimeter portion 162, circular lip 164 and thecurved section 174 can conveniently be provided as follows. The inneredge of the container upper wall 132 is preformed to form the circularlip 164, and the collar 152 is also preformed with its semi-circularperimeter portion 162. The upper curved section of the entry housing 148can either be preformed with its upper curved section 174, or this curve174 can be made at the time of assembly.

Initially, the entry housing 148 with the tube 140 already mountedtherein is positioned within the container 112 with the upper edgeportion 174 of the housing sidewall 168 overlying the container lip 164.Then the mounting collar 152, with the seal and mounting member 154 andthe valve stem 156 already mounted thereto is positioned in the openingat the upper end of the container 112, with the collar perimeter portion162 overlying the curved portion 174. After this, an expanding tool ispositioned within the collar 152 and is operated to push radiallyoutwardly against the sidewall 163 of the collar 152 at approximatelythe location 175 to expand the collar sidewall at the location outwardlya short distance so that it forms a slanted wall section that engagespart of the underside of the container lip 164. This secures the collar152 in place. Also, this makes a tight fit between the collar perimeterportion 162, the container lip 164 and the curved portion 174 so that aproper seal is formed. This seal is formed not only with respect to thechamber 116, but also this forms a seal within the entry chamber 150.

The valve seal and mounting member 154 in terms of function has twoportions, namely a lower seal portion 178, and second a mounting portion180. The mounting portion 180 has a center opening 181 and fits withinthe inner circular edge of a lower wall 182 of the mounting collar 152.The mounting portion 180 has a lip or shoulder 183 that extends over theinner edge of the wall 182, and the seal portion 178 fits against thelower surface of the wall 182.

In this manner, the mounting portion 180 serves to support the valvestem 156 in the opening 181, with the valve stem supporting the valvehandle portion 158 and the end nozzle section 160. The seal portion 178forms a seal not only for the inlets of the valve stem 156, but alsoforms a seal with the lower collar wall 182.

The describe the valve stem 156, there is a vertical tubular portion 184that has as its lower end a closure disk or plate 186 which in theclosed position abuts against the lower circular edge 188 of the sealportion 178. The lower part of the tubular portion 184 of the stem 156has two laterally extending openings 189. In the closed position of FIG.6, the seal portion 178 closes these two openings 189. The upper endportion 190 of the tubular stem portion 184 has external threads so thatit can be connected to the handle portion 158.

The valve handle portion 158 has a lower cylindrical mounting portion192 which is internally threaded and fits in threaded engagement ontothe upper end 190 of the valve stem tubular portion 184. This handleportion 158 has two outwardly extending actuating members or handlemembers 194 extending in opposite directions from one another, each ofthese members 194 having an upwardly concavely curved surface 196 to beengaged by the fingers of the person.

A circumferential shoulder 198 on the valve stem 156 engages the upperend of the positioning spring 159, and the lower end of the positioningspring 159 bears against the upper surface of the collar wall 182. Thus,when the handle portion 158 is depressed downwardly, the spring 59 isdeformed downwardly so as to provide a restoring force to move thehandle portion 158 upwardly when the handle portion 158 is released. Theupper part of the handle portion 158 comprises a tubular extension 200that is connected to the end nozzle section 160.

The tubular portion 184 of the valve stem 156 defines an upwardlyextending through passageway 202 which lead into an expanded passagewaysection (generally designated 204) formed in the upper end portion 200of the handle portion 158 in conjunction with the upper nozzle section160. With reference to FIG. 8, the valve handle portion 158 is formed sothat immediately above the threaded mounting portion 192, there is aninitial lower passageway portion 206 which receives the very upper endof the valve stem 176, and defines an upper passage entry portion 208.This passageway portion 208 lead into an upwardly and outwardlyexpanding passageway portion 210 which in turn leads into an insidesurface portion 212 of a greater diameter, the surface portion 212 ineffect defining an expansion chamber 214 which is part of the expandedpassageway portion 204. From the chamber 214, the passageway portion 204diminishes in cross-sectional area in an upward direction, and thisuppermost converging passageway section is formed by the nozzle section160.

This nozzle section 160 is made of two molded parts which are halfsections which fit within the valve handle upper portion 200 and arejoined to one another along a vertical center plane as two side by sidesections. There is a lowermost circular portion 216 having its diametersmaller than the diameter of the chamber surface portion 212.Immediately above the section 216 there is a further necked down section218, and this connects to an upwardly and inwardly slanted portion 219to a further upward portion 220 which defines a yet smaller cylindricalpassageway section 222 that leads into an end nozzle portion 224.

This end nozzle section 224 comprises two plate sections or flanges 226which define therebetween an elongate laterally extending slot 228.These two plate sections 226 converge toward one another to form the endslot 228. In addition, as can be seen in FIG. 6, at opposite ends of thetwo flanges 226 there are laterally and outwardly extending connectingportions 230 which have outwardly slanting upwardly facing surfaceportions 232. Thus, it can be seen that this passageway at 222 istransformed in an upward direction from a cylindrical passageway to apassageway which converges in one direction (caused by the plates 226slanting toward one another), and expands in a direction 90° from thefirst direction (caused by the outward slant of the surfaces 232 of theconnecting portions 230).

The texture material 122 within the container 112 is a mixture thatcomprises a carrier fluid component and a particulate material havingparticles which are mixed throughout the carrier fluid. The gaseouspropellant 124 in the upper chamber portion 120 is at a predeterminedpressure level which is above ambient pressure (e.g. 100 PSI).

The particulate material is made from an expanded polystyrene having apredetermined maximum particle size (e.g. the larger particles averagingabout ⅛ of an inch across), with each particle being compressible to asmaller particle size dimension. (A compression test of a preferred formof the material indicates that under 100 PSI pressure, the volume isdecreased from 100% down to 25% of the original volume). Commonly, theparticles of the mixture has a variety of sizes to provide a texturesurface having different particle sizes. While this polystyrene materialis the preferred material, within the broader scope of the presentinvention other materials (desirably compressible materials) could beused.

To describe the operation of the present invention, the apparatus 110 isprovided to the end user with the texture material mixture containedwithin the container, and with the particulate material distributedthroughout the fluid component. The texture material 22 occupies atleast approximately one half of the volume of the chamber 116 orpossibly somewhat more than half the volume of the chamber 116. Sincethe apparatus 110 is commonly operated in a vertical position to applythe spray texture material upwardly to a ceiling, the texture material122 is normally positioned in the bottom of the container 112. In use,the apparatus 110 is grasped in a person's hand, with two of theperson's fingers engaging the upper surfaces 196 of the handle members194 to depress the handle portion 158 and the valve stem 156 against theurging of the spring 159. This moves the closure disk or plate 186downwardly to expose the openings 188. The pressurized gas 124 pushesthe texture material 122 upwardly through the tube 140 into the entrychamber 150. It has been found that the particular arrangement as shownherein functions to reliably pass the particles in the mixture throughthe lateral valve openings 188 and into the passageway 202 defined bythe valve stem 156.

The texture material 124 flows through the passageway 202 of the valvestem 156 into the expansion chamber 204, and thence upwardly through theconverging passageway portion defined by the nozzle portion 160. As thetexture material flows into the upper nozzle portion, the texturematerial expands laterally in the end nozzle portion 224 in onedirection, while the passageway is diminished in the direction 90° tothe first direction. The material exiting from this elongate nozzleopening 228 is disbursed upwardly and somewhat laterally to be appliedto the surface (which, as indicated previously, would usually be aceiling to which an acoustic texture material is applied.

As described above, the texture mixture may comprise one or more thefollowing ingredients:

-   -   a. a thickener that controls the film integrity of the        composition;    -   b. a surfactant;    -   c. a defoamer to facilitate the processing and minimize bubbles        when spraying;    -   d. an anti-microbial component;    -   e. a pigment component (often a whitener);    -   f. a commercially available ceiling texture material with the        particles distributed therein;    -   g. water.

When deposited on the surface, the texture material hardens to form thefinished textured surface.

VI. Fourth Embodiment

A fourth embodiment of the present invention is illustrated in FIGS. 11and 12. Components of this fourth embodiment which are similar tocomponents of the third embodiment will be given like numericaldesignations, with an “a” suffix distinguishing those of the secondembodiment.

In this fourth embodiment, the apparatus 110 a comprises a container 112a and a discharge assembly 114 a. However, the discharge assembly 114 adoes not have the feed tube 140 and the entry chamber housing 148 thatare present in the third embodiment 110, shown in FIGS. 6 through 10.

Another difference in this fourth embodiment is that the texturematerial 122 a, instead of being positioned by gravity in the bottom ofthe container 112 a, is contained in a flexible sack-like container 240that forms the texture material chamber 118 a immediately adjacent tothe valve section 138. Further, the propellant 124 a is separated fromthe texture material 122 a by the flexible container 240, and thispropellant 124 a is a vaporizable liquid which when under pressure inthe container remains liquid, but with a small pressure reductionvaporizes to form a gas which pushes against the texture material 122 a.

In order to prevent the flexible sack-like container 240 from deformingin a manner to close off the intake openings to the valve, there isprovided an elongate spring 242 a which is positioned vertically in thetexture material chamber 118 a. The upper edge of the flexible container240 is placed in a curve over the inner rounded edge 164 a of thecontainer upper wall 132 a, and beneath the curved perimeter portion 162a of the collar 152 a, in the same manner as the rounded portion 174 ofthe entry chamber housing of the third embodiment.

As in the third embodiment, there is the valve section 138 a whichcomprises a mounting collar 152 a, the seal and mounting member 154 a,the valve stem 156 a, the valve handle portion 158 a, and the end nozzlesection 160 a. All of these components 152 a through 160 a aresubstantially the same as in the third embodiment, except that thepositioning spring 159 of the third embodiment is omitted. In its place,the seal and mounting member 154 is provided with an upwardly extendingresilient tube portion 244 that is made integral with the seal andmounting member 154. When the handle portion 158 a is depressed, thisdeforms this resilient tubular portion 244 outwardly so as to be axiallycompressed.

In operation, when the valve section 138 a is moved to the openposition, the propellant 124 a pushes the texture material 118 a intothe valve openings 188 a and out and upwardly through the passageway 202a, to exit out the nozzle opening 228 a. The manner in which this occursis believed to be evident from the description in the third embodiment,so this will not be repeated in connection with this fourth embodiment.

As indicated above, as the volume of the texture material 122 adecreases, the flexible container 240 collapses, with the propellant 124a expanding in the propellant chamber 120 a.

VII. Fifth Embodiment

Referring now to FIG. 13 of the drawing, depicted therein at 320 a is aspray texturing device constructed in accordance with of, and embodying,the principles of a fifth embodiment of the present invention. Thisdevice 320 a is adapted to contain and dispense a hardenable material322. The hardenable material 322 comprises a commercially availableceiling texture material 324 containing polystyrene particles 326.

The aerosol device 320 a basically comprises a container 328, a cap 330,and a collection tube 332. The cap 330 mounts the collection tube 332within an opening 334 in the container 328 such that a first end 336 ofthe collection tube 332 is within the container 328 and a second end 338of the collection tube 332 extends out of the container 328. Thehardenable material 322 is contained within a chamber 340 defined by thecontainer 328. The collection tube first end 336 extends into thehardenable material 322.

A port 342 is formed in the container 328 to allow pressurized air to beintroduced into the chamber 340. When the container 328 is in theupright position shown in FIG. 13, the introduction of pressurized airthrough the port 342 into the chamber 340 forces the hardenable material322 into the collection tube first end 336, through the collection tube332, and out of the collection tube second end 338. Accordingly, theaerosol device 320 a in its most basic form employs a compressed inertgas such as air to force a hardenable material containing particulatesupwardly out of the container 328.

VIII. Sixth Embodiment

Referring now to FIG. 14, depicted therein at 320 b is sixth embodimentof an aerosol device constructed in accordance with, and embodying, thepresent invention. The aerosol device 320 b is constructed and operatesin the same basic manner as the device 320 a above. However, the device320 b further comprises a manifold 344 at which a vapor tap tube 346 isconnected to the dispensing tube 332. Compressed air injected into thetube 346 will mix with the hardenable material 322 exiting thedispensing tube 322 near the dispensing tube second end 338 to atomizethe hardenable material 322 as it leaves the tube 332. By vaporizing thehardenable material 322 as it leaves the dispensing tube 332, thehardenable material 322 sprays as it leaves the device 320 b as is thetendency with the material 322 as it leaves the aerosol device 320 adescribed above. While a stream of hardenable material 322 can be usedto patch a ceiling, the spray developed by the aerosol device 320 b moreevenly and effectively distributes the hardenable material onto theceiling. A valve 348 was employed to vary the amount of air used toatomize the hardenable liquid 322.

IX. Seventh Embodiment

Referring now to FIGS. 15 and 16, depicted therein is yet anotherexemplary aerosol device 320 c constructed in accordance with, andembodying, the principles of a seventh embodiment of the presentinvention. Elements of the aerosol device 320 c that are the same asthose of the device 320 a are assigned the same reference character andwill be described herein only to the extent that they differ from thecorresponding element of the device 320 a.

The aerosol device 320 c fundamentally differs from the devices 320 aand 320 b described above in that the device 320 c employs a vaporizableliquid 350 to propel the hardenable material 322 from the container 328.The vaporizable liquid 350 can be a hydrocarbon material as is wellknown in the art.

The device 320 c further comprises a valve assembly 352 for allowing theoperator to open or close a dispensing passageway 354 through which thehardenable material 322 is discharged.

When the valve assembly 352 is operated to establish the dischargepassageway 35, the vaporizable material 350 vaporizes and becomes a gaswhich collects in an upper portion 356 of the chamber 340. This gas actson the hardenable material 322 to force this material through thedischarge passageway 354 and out of the container 328.

In this case, with a liquid hydrocarbon used as a propellant, a texturematerial 354 comprising particles 356 of material other than polystyreneshould be used. The liquid hydrocarbon will dissolve polystyreneparticles. Accordingly, the particles 356 should be formed of cork orother materials that will not be dissolved by the liquid hydrocarbons.In this case, the aerosol device 320 c is not optimized for use as aceiling texture material dispenser because the particles 356 will eitherbounce off of the ceiling or will not adequately match the texture ofthe surrounding ceiling.

The valve assembly 352 is constructed and operates in the same basicmanner as the valve section 138 described above with reference to FIG. 6and will be described herein only briefly. The valve assembly 352basically comprises a housing 362, a valve seat 364, and a valve member366 having a valve stem 368.

The discharge tube 332 is connected to the valve housing 362. The valveassembly 352 is opened by downwardly pressing the valve stem 368. Whenthe valve is so opened, the discharge passageway 354 is defined by thedischarge tube 332, valve housing 362, and valve member 366.

X. Eighth Embodiment

Referring now to FIG. 17, depicted at 320 d therein an eighth embodimentof an aerosol device constructed in accordance with, and embodying, theprinciples of the present invention. The aerosol device 320 d isconstructed in a manner basically similar to that of the device 320 adescribed above. Components of the device 320 d that are the same asthose of the device 320 a described above will be assigned the samereference character and described below only to the extent necessary fora complete understanding of the operation of the device 320 d.

The aerosol device 320 d comprises a piston member 370 arranged withinthe container 328 such that the chamber 340 is divided into a firstportion 372 and a second portion 374. The hardenable material 322including the ceiling texture material 324 comprising polystyreneparticles 326 is arranged in the first portion 372 of the chamber 340.The chamber second portion 374 contains a propellant material such as avaporizable hydrocarbon liquid or a compressed inert gas such as air ornitrogen.

A valve assembly 378 is mounted to the cap 330 within the opening 334 inthe canister 328. This valve assembly 378 comprises a valve seat 380 anda valve member 382 having a valve stem 384. Depressing the valve stem384 downwardly allows the hardenable material 324 within the chamberfirst portion 372 to flow through an exit passageway 386 to the exteriorof the container 328. The discharge passageway 386 is defined by thevalve member 382. When the valve assembly 378 is opened, the propellantmaterial 376 in the chamber second portion 374 is allowed to expand. Asit expands, the propellant material 376 acts on the piston member 370 toforce the hardenable material 324 out of the canister 328.

The piston member 370 thus separates the hardenable material 324 fromthe propellant material 376, allowing the use of liquid hydrocarbons asa propellant material. However, it should be recognized that a perfectlyfluid-tight seal around the perimeter of the piston member 370 cannot bemaintained; thus, over time, the propellant material 376 may seep intothe chamber first portion 372 and, if the propellant material 376 is aliquid hydrocarbon and the particles 326 are polystyrene, dissolve theseparticles 326.

XI. Dispersion Means

With conventional texture material without polystyrene particles, theliquid propellants used gassify as the exit the aerosol device with thetexture material; the gassifying liquid propellant causes the texturematerial to exit the aerosol device in the form of a conical sprayrather than a stream.

Because the acoustic texture material dispensed by any of the variousdispensing assemblies described herein uses compressed inert gas as apropellant rather than a conventional liquid propellant, the texturematerial is not broken up into a spray and thus tends to exit theaerosol device in a stream rather than a spray.

Accordingly, dispersion means are preferably employed to disperse thetexture material as it exits the aerosol device such that the texturematerial exits in a fan-shaped or conical spray. Dispersion means suchas are depicted in FIGS. 18-31 and as described below may be used withany of the dispensing assemblies or aerosol devices described herein toprevent the acoustic texture material from being deposited in the formof a narrow stream.

Referring to FIGS. 18 and 19, depicted therein at 420 a is an exemplarydispersion assembly constructed in accordance with, and embodying, theprinciples of the present invention. Referring initially to FIG. 19,depicted at 422 is a hollow tube corresponding either to a second end ofa discharge tube such as the discharge tube 322 shown and described inrelation to FIGS. 13 and 14, or a stem portion of a valve assembly suchas the valve assembly 352 and 378 described and shown in FIGS. 16 and17. This hollow tube 422 defines a discharge axis A shown by brokenlines in FIG. 19.

The dispersion assembly 420 a is mounted on this tube 422. Thedispersion assembly 420 a comprises a mounting member 424 and adeflecting member 426. A discharge opening 428 is formed in the mountingmember 424.

The mounting member 424 is attached to the tube 422 such that thedischarge opening 428 is aligned with a discharge passageway 430 definedby the tube 422. The discharge opening 428 comprises a cylindrical upperportion 432 and a frustoconical lower portion 434. The lower portion 434reduces the diameter of the discharge passageway 430 from the innerdiameter of the tubular member 422 to the diameter of the opening upperportion 432. The discharge opening 428 thus forms a nozzle thataccelerates the hardenable material flowing along the dischargepassageway.

The deflection member 426 is generally hook-shaped and connected to theattachment member such that a portion 436 thereof coincides with thedischarge axis A.

Accordingly, as the hardenable material passes through the dischargeopening 428, it contacts the deflection member 426 such that at least aportion of the hardenable material has a vector component that radiallyextends outward from the discharge axis A.

The dispersion assembly 420 a thus causes the hardenable material toform a spray rather than a stream. This makes it easier for the user toapply hardenable material to a surface in an even pattern.

Handles 425 are formed on the attachment member 424 to allow the user todisplace the tubular member 422 downwardly along the discharge access A.

Referring now to FIGS. 20-22, depicted at 420 b therein is yet anotherexemplary dispersion assembly constructed in accordance with, andembodying, the principles of the present invention. The dispersionassembly 420 b is constructed and operates in the same basic manner asthe dispersion assembly 420 a described above; accordingly, thedispersion assembly 420 b will be described herein only to the extentthat it differs from the dispersion assembly 420 a.

The dispersion assembly 420 b comprises a deflection member 438extending from the attachment member 424 above the discharge opening428. The deflecting member 438 has a deflecting surface 440 formedthereon. The deflecting surface 440 is arranged such that it intersectsthe discharge axis A. Accordingly, as hardenable material flows alongthis axis A, the material will contact this deflecting surface 440.After it has been so deflected, at least a portion of the hardenablematerial will have a vector component in a direction radially extendingfrom the discharge axis A. As with the dispersion assembly 420 adescribed above, the dispersion assembly 420 b will thus generate aspray of hardenable material that facilitates the application of thismaterial on the surface to be textures.

FIGS. 23 and 24 depict an exemplary dispersion unit 420 c that isconstructed in accordance with, and embodies, the principles of thepresent invention. This dispersion unit 420 c operates in the same basicmanner as the dispersion assembly 420 a and will be described hereinonly to the extent that it differs therefrom.

The dispersion unit 420 c comprises a dispersion member 424. Thedispersion member 424 has formed therein a nozzle passageway 442comprising a vertical portion 444 aligned with the discharge access Aand a radial portion 446 arranged at an angle to the discharge access A.A dispersion surface 448 is arranged at the end of the vertical portion444 and forms a part of the radial portion 446. As the hardenablematerial flows along the discharge access A, it will be redirected suchthat it has a vector component radially extending from the dischargeaccess A.

The radial passageway 446 is further defined by a lower surface 450. Asshown in FIG. 24, the deflecting surface 448 terminates approximatelymidway along the bottom surface 450.

In FIG. 25, there is depicted yet another exemplary dispersion member420 d constructed in the same basic manner as the dispersion member 420c described above. In the dispersion member 420 d, the radial passageway446 is defined by divergent sidewalls 452 and 454. These divergingsidewalls 452 and 454 allow the hardenable material to fan out as itexits the discharge opening 428.

In FIGS. 26 and 27, there is depicted yet another exemplary dispersionmember 420 e constructed in the same basic manner as the dispersionmember 420 d described above. The dispersion member 420 e furthercomprises a deflecting member 456 arranged to partially cover thedischarge opening 428. The deflecting member 456 is generally triangularin shape, with a point being formed substantially equidistant betweenthe diverging sidewalls 452 and 454 defining the radial passageway 446.Configured as just described, the deflecting member 456 deflects atleast a portion of the hardenable material coming out of the dischargeopening 428 such that at least a portion of the hardenable material hasa vector component that radially extends from an access B of the radialpassageway 446. This results in a wider dispersal of hardenable materialthroughout the spray pattern formed by the dispersion member 424.

Referring now to FIGS. 28 and 29, depicted at 420 f therein is yetanother exemplary dispersion member constructed in accordance with, andembodying, the principles of the present invention. The dispersionmember 420 f operates in a manner similar to the dispersion assembly 420b described above.

In particular, a dispersion member 458 is arranged adjacent to the upperportion 432 of the discharge opening 428. In the discharge member 420 f,the exit opening 428 is rectangular in shape and the deflecting member458 is arranged with a deflecting surface 464 formed thereon arranged todeflect all of the hardenable material exiting through the dischargeopening 428. However, the deflecting surface 464 does not overhang anupper surface 466 of the dispersion member 424 f; accordingly, thehardenable material is not channeled in a direction radial to thedischarge access A and is allowed to develop into a spray thatfacilitates application of the hardenable material to the surface to becovered.

Referring now to FIGS. 30 and 31, depicted therein at 420 g is yetanother exemplary dispersion member constructed in accordance with, andembodying, the principles of the present invention. This dispersionmember 420 g defines a passageway 468 comprising a short verticalportion 470 and a fan-shaped radial portion 472. The radial portion 472has diverging sidewalls 474 and 476 and parallel upper and lower walls478 and 480. Extending between the upper and lower walls 478 and 480 area plurality of deflecting member 482 designed to deflect and slow downat least a portion of the hardenable material exiting through thedischarge opening 428. The fan-shaped arrangement of the radialpassageway 472 along with the deflecting member 482 results in a sprayof hardenable material that facilitates the application of this materialonto a surface.

XII. Ninth Embodiment

Referring now to FIG. 32 a, depicted at 500 therein is a ninthembodiment of a dispensing system constructed in accordance with, andembodying, the principles of the present invention. In addition to afluid portion as generally described above, the dispensing system 500includes a mechanical portion 502 that allows the acoustic texturematerial of the fluid portion to be dispensed in predetermined meteredamounts.

The mechanical portion 502 comprises a container assembly 504, a valveassembly 506, an actuator member 508, and a metering assembly 510.

A container assembly 504 comprises a container 512, a cap 514, and amounting flange 516.

The valve assembly 506 comprises a valve housing 518, a valve stem 520,a valve spring 522, and a valve seal 524.

The metering assembly 510 comprises a metering member 526 and aplurality of guide flanges 528 extending from the valve housing 518.

The actuator member 508 is attached to the valve stem 520 by threads,adhesives, or the like. The actuator member is configured such that theuser can depress downwardly on the actuator member 508 and cause thevalve stem 520 to move downwardly along a longitudinal axis x of themechanical portion 502.

The cap 514 and mounting flange 516 are attached to the container 512 ina conventional manner. The valve housing 518 is attached to the mountingflange 516 such that the valve housing 518 resides within the container512. The valve housing 518 is connected to a pick-up tube such as thetube 46 described above, which creates a fluid path from the bottom ofthe container 512 to the valve housing 518 as will be described infurther detail below.

The valve seal 524 is mounted to the cap 514, and the valve stem 520 ismounted to the valve seal 524 such that the valve stem 520 moves alongthe axis x as generally described above. The valve spring 522 isarranged to oppose motion of the valve stem 520 downward along the axisx.

The metering member 526 is an annular or ring shaped member that isarranged about a lower portion of the valve stem 520 between a stemportion 520 a of the valve stem 520 and the valve seal 524. A releaseflange 530 extends from an upper portion of the metering member 526.

A release projection 532 is formed on a lower inner portion of themetering member 526. A similarly shaped release groove 534 is formedabout the valve stem 520 adjacent to the stem portion 520 a. The releaseprojection 532 is designed to engage the release groove 534, but can bedisengaged therefrom by deliberate application of manual force thattends to move the metering member 526 away from the stem portion 520 a.

The metering member 526 further defines a metering surface 536 that hassubstantially the same cross-sectional area as an outer surface of thestem member 520.

Referring again to FIG. 32A, the mechanical portion 502 is shown in whatwill be referred to as a storage state. In the storage state, themetering member 526 engages the valve seal 524 to prevent fluid fromexiting the container 512 through the valve assembly 506.

The propellant within the container 512 acts on the texture materialthere within to force the texture material through a housing inlet 538in the valve housing 518 and into a housing chamber 540.

To dispense texture material from the mechanical portion 502, theactuator member 508 is displaced downwardly along the axis x such thatthe metering member 526 disengages from the valve seal 524. When thisoccurs, pressurized fluid within a housing chamber 540 defined withinthe valve housing 518 may flow through a stem inlet 542 in the valvestem 520, into a stem passageway 546 in the valve stem 520, and out ofthe mechanical portion 502 through an outlet chamber 548.

Because the release projection 532 is engaged with the release groove534 to begin with, the metering member 526 moves downward with is thevalve stem 520 creating the dispensing path DP along which the texturematerial passes as it exits the container 512. At the point depicted inFIG. 32B, the release flange 530 engages an upper portion of the guideflanges 528 such that the metering member 526 can no longer movedownward along the axis x.

Referring now to FIG. 32C, continued displacement of the actuator member508 such that the valve stem 520 moves further downward along the axis xresults in the release projection 532 leaving the release groove 534such that the metering member 526 no longer moves in tandem with thevalve stem 520. The valve stem 520 thus moves relative to the meteringmember 526 to a point shown in FIG. 32C in which the stem inlet 542 iscompletely covered by the metering surface 536. At this point, texturematerial is prevented from flowing from the housing chamber 540 throughthe stem inlet 542. This effectively stops texture material from flowingout of the container 512.

During the downward movement of the stem member 520, the valve spring522 is compressed. Accordingly, releasing the actuator member 508 allowsthe valve spring 522 to urge the valve stem 520 upward. Friction betweenthe valve stem 520 and the metering surface 536 causes the meteringmember 526 to move upward with the valve stem 520 until the meteringmember 526 again comes in contact with the valve seal 524. Thisconfiguration is shown in FIG. 32D.

At this point, the metering member 526 can no longer move upward withthe valve stem 520. The valve spring 522 continues to move the valvestem 520 upward until the stem portion 520 a thereof engages themetering member 526 as shown in FIG. 32A. At this point, the releaseprojections 532 engage the release groove 534 such that, if the valvestem 520 again is moved downward, the metering member 526 will becarried therewith. Accordingly, the mechanical portion 502 is returnedto its predispensing state shown in FIG. 32A and is ready to be usedagain.

The mechanical assembly 502 described above requires no special skill bythe user for dispensing the texture material within the container 512.The user must simply press downwardly on the actuator member 508 untilthe valve stem 520 bottoms out as shown in FIG. 32C, then releases theactuator member 508. If these minimal directions are followed, themechanical portion 502 will dispense a quantity of texture material thatis a function of the pressure and volume of the inert gas used as apropellant, the speed at which the stem member 520 is moved downward,the size of the stem inlet 542, and the amount the stem member 520 isallowed to travel before its stem inlets 542 are covered by the meteringsurface 536. These parameters can be adjusted so that a reasonablyconsistent amount of texture material is dispensed by even aninexperienced user.

XIII. Tenth Embodiment

Referring now to FIGS. 33A-D, depicted therein at 550 is a tenthembodiment of a dispensing system constructed in accordance with, andembodying, the principles of the present invention. This dispensingsystem 550 comprises a fluid portion as described above, and amechanical portion 552. The mechanical portion 552 is designed todispense a controlled, metered amount of texture material.

In particular, the mechanical portion 552 comprises a container assembly554, a valve assembly 556, an outlet assembly 558, and a meteringassembly 560. A container assembly 554 is adapted to contain the fluidportion as described above. The valve assembly 556 is mounted on thecontainer assembly 554 and operates in a closed configuration in whichfluid may not exit the container assembly 554 and an open configurationin which fluid is allowed to exit the container assembly 554. The outletassembly 558 disperses the texture material exiting the containerassembly 554 through the valve assembly 556. The metering assembly 560engages the valve assembly 556 to control the opening and closing of thevalve assembly such that only a limited amount of texture material isreleased when the valve assembly is used as intended.

The container assembly 554 comprises a container 562 and a cap 564mounted on the container 562 along a longitudinal axis x thereof.

The valve assembly 556 comprises a valve housing 566, a valve stem 568,a valve spring 570, and a valve seal 572. The valve housing 566 ismounted to the container 562 and cap 564 such that the interior of thecontainer 562 is divided into two separate chambers. As with the ninthembodiment discussed above, a pick-up tube is connected to the valvehousing 566 to allow fluid at the bottom of the container assembly 554to enter the valve housing 566.

The valve seal 572 is mounted on the cap 564, and the valve stem 568extends through the valve seal 572. The valve seal prevents fluid fromflowing out of the valve housing 566 between the valve stem 568 and thecap 564.

The valve spring 570 is mounted between the cap 564 and the valve stem568 such that the spring 570 urges the valve stem upward. When no forceis applied to the valve stem 568, the valve spring 570 urges the valvestem 568 upward such that the valve stem 568 engages the valve seal 572,in which case the valve assembly 556 is in its closed position.

The outlet assembly 558 comprises an actuator member 574, and outletmember 576, an outlet cap 578, and an actuator return spring 580. Theoutlet member 576 is rigidly attached to the valve stem 568 by threadingand/or adhesives, such that movement of the outlet member 576 istransferred to the valve stem 568.

The outlet member extends through the actuator member 574 such thatrelative movement between the outlet member 576 and the actuator member574 is possible.

The outlet cap 578 is attached to the outlet member 576 to form adispersing means as texture material exits the mechanical portion 552.

The actuator return spring 580 is arranged between the cap 564 and theactuator member 574 to oppose downward movement of the actuator member574.

The metering assembly 560 comprises a metering member 582 and a releasemember 584. The metering member 582 is attached to the outlet member576. Accordingly, movement of the metering member 582 will betransmitted through the outlet member 576 to the stem member 568. Itshould be noted that, in the exemplary dispensing system 550 describedherein, the valve stem 568, outlet member 576, outlet cap 578, andmetering member 582 all form a rigid assembly and can be made as onepiece. For manufacturing reasons, however, this assembly comprises fourseparate molded plastic parts in the exemplary dispensing system 550.

The release member 584 is fixed relative to the cap 564. In theexemplary assembly 550, the actuator return spring 580 physicallyengages the release member 584 at its lower end and thus holds therelease member 584 against the cap 564. Again, this is convenient formanufacturing purposes, but the cap 564 and release member 584 couldconceivably be formed by one integrally formed part.

Formed on the actuator member 574 is an actuator surface 586. Extendingfrom the metering member 582 are metering projections 588. Theseprojections 588 are canted outwardly from the longitudinal axis x, butare sized, dimensioned, and made of a material that allows theseprojections 588 to deflect inwardly towards the axis x.

Formed on the release member 584 is a release surface 590. The releasesurface 590 is spaced directly below the actuator surface 586.

FIG. 33A shows the mechanical portion 552 in a predispensing state inwhich the valve assembly 556 is closed. Applying a downward force on theactuator member 574 causes the actuator surface 586 to engage themetering projections 588 and force the valve stem 568 downward asperhaps best shown in FIG. 33B. When the valve stem 568 moves downward,it disengages from the valve seal 572 and forms a dispensing path DP.This dispensing path DP allows pressurized texture material within thevalve housing 566 to enter a stem inlet 592 formed in the valve stem568, flow through a stem passageway formed in the valve stem 568, andenter an outlet chamber 596 defined by the outlet member 576 and outletcap 578. The outlet chamber 596 is in communication with the exterior ofthe container 562 through an outlet opening 598 defined by the outletcap 578. The outlet opening 598 is sized and dimensioned to disperse thetexture material as it leaves the mechanical portion 552.

As shown in FIG. 33B, as the valve stem 568 moves downward, it carriesthe metering projections 588 with it such that these projections 588come in contact with the release surface 590 on the release member 584.

Referring now to FIG. 33C, it can be seen that continued downwardmovement of the valve stem 568 causes the release surface 590 todisplace the metering fingers 588 towards the longitudinal axis x suchthat these fingers 588 are disengaged from the actuator surface 586. Atthis point, the actuator surface 586 comes into contact with the releasesurface 590.

As the valve stem 568 moves downward, it compresses the valve spring570. Accordingly, when the metering fingers 588 become disengaged withthe actuator surface 586, the valve spring 570 urges the valve stem 568upward. The metering projections 588 slide along the actuator member 574as shown in FIG. 33D and allow the valve spring 570 to force the valvestem 568 back into its original, uppermost position in which it engagesthe valve seal 572 to prevent fluid from flowing out of the container562.

During this process, the actuator member 574 has compressed the actuatormember return spring 580. Accordingly, the user need only release theactuator member 574, and the actuator return spring 580 will force theactuator member 574 up relative to the valve stem 568 and meteringmember 582. The actuator member 574 thus returns to its initial positionin which the actuator surface 586 is located above the meteringprojections 588. The metering projections 588 are thus allowed to returnto their original position in which they are more severely cantedoutwardly relative to the longitudinal axis x. The mechanical portion552 is thus ready to dispense another metered portion of texturematerial.

As with the ninth embodiment discussed above, the dispensing system 550of the tenth embodiment allows the user to press firmly and continuouslydown to dispense a limited, controlled, and metered amount of texturematerial.

The amount of texture material released is determined by the samefactors discussed above with reference to the ninth embodiment.

XIV. Eleventh Embodiment

Referring now to FIGS. 34-37, depicted therein at 600 is a eleventhembodiment of the dispensing system constructed in accordance with, andembodying, the principles of the present invention. The dispensingsystem 600 comprises a fluid portion as described above and a mechanicalportion 602, a portion of which is depicted in the drawing.

The mechanical portion 602 comprises a container assembly 604, a valveassembly 606, an outlet assembly 608, and a metering assembly 610.

The valve assembly 606 is mounted on the container assembly and operablein open and close configurations. When the valve assembly 606 is in itsclosed configuration, fluid is prevented from leaving the containerassembly 604. The outlet assembly 608 is mounted onto the valve assembly606 such that, when the valve assembly 606 is in its open configurationfluid, and in particular acoustic texture material, is allowed to flowout of the container assembly 604 through the outlet assembly 608.

The metering assembly 610 controls the valve assembly 606 such that apredetermined, metered amount of texture material is dispensed.

The container assembly 604 comprises a container 612 and a cap 614. Thevalve assembly 606 comprises a valve housing 616, a valve stem 618, avalve spring 620, and a valve seal 622. The cap 614 is mounted on thecontainer 612 and the valve seal 622 is mounted on the cap 614. Thevalve stem 618 extends through the valve seal 622. The valve seal 622 ismade of a resilient material that engages the cap 614 and the valve stem618 such that fluid is not able to flow out of the container 612 betweenthe cap 614 and the valve stem 618.

The valve housing 616 is mounted to the container assembly 604 such thatit is within the container 612 below the cap 614. As with the valvehousings of the ninth and tenth embodiments described above, the valvehousing 616 is connected to a pick-up tube that extends to the bottom ofthe container 612. As generally discussed above, the pressurizedpropellant material is located at the top of the container 612 and thetexture material at the bottom of the container 612. Accordingly, thepressurized propellant material forces the texture material through thepick-up tube such that pressurized texture material is present in thevalve housing 616.

The valve spring 620 is arranged between the cap 614 and the valve stem618 such that the valve spring 620 urges the valve stem 618 upward suchthat the valve assembly 606 is normally biased into its closed position.When the valve assembly 606 is in its closed position, the valve stem618 engages the valve seal 622 as shown in FIG. 34A.

The outlet assembly 608 comprises an actuator member 624, and outletmember 626, and an actuator return spring 628. The outlet member 626 isrigidly attached to the valve stem 618 by threads, adhesive, or the likesuch that movement of the outlet member 626 causes movement of the valvestem 618. The actuator member 624 is free to move relative to the valvestem 618 and outlet member 626, with the outlet member 626 extendingthrough the actuator member 624. The actuator return spring 628 isarranged to urge the actuator member 624 upward; when the actuatormember 624 is moved downward, the actuator return spring 628 iscompressed.

The metering assembly 610 comprises a trigger assembly 630 and a releaseassembly 632. The trigger assembly 630 comprises a trigger member 634and a trigger spring 636. The release assembly 632 comprises a releasemember 638 configured as will be described below.

The trigger member 634 comprises a plurality of guide fingers 640, aplurality of trigger fingers 642, and a plurality of release fingers 644that extend downwardly from a trigger plate 646. The guide finger 640and trigger finger 642 are shown in FIG. 34 and in the horizontalsection view of FIG. 36. The release fingers 644 are shown in FIG. 35 aswell as in the horizontal section view of FIG. 36. The exemplarymechanical portion 602 comprises three each of these guide fingers 640,trigger finger 642, and release finger 644. More or fewer of thesefingers 640-644 may be used, but the use of three each represents adesirable blend of balance during operation and manufacturability.

As shown in FIGS. 34, 35, and 37, an intermediate flange 648 is formedon the outlet member 626.

The release member 638 comprises a guide cylinder 650, a plurality ofsupport posts 652, and a plurality of release posts 653 that extendupwardly from a base plate 654. The base plate 654 is configured tosnugly be received within the cap 614. The guide cylinder 650 extendsupwardly a distance slightly greater than the height of the supportposts 652 and release posts 653.

An actuator surface 656 is formed on the actuator member 624. As shownin FIG. 34, a trigger surface 658 is formed on each of the triggerfingers 642. FIG. 35 shows that a cam surface 660 is formed on each ofthe release fingers 644. And in FIG. 34, it can be seen that a supportsurface 662 and release surface 664 are formed on each of the supportposts 652.

The actuator member 624 comprises first and second bearing surfaces 666and 668 and an actuator cylinder 670.

The metering assembly 610 is assembled together with the containerassembly 604, valve assembly 606, and outlet assembly 608 as follows.After the valve assembly 606 has been mounted onto the containerassembly 604 and the outlet member 626 attached to the stem member 618as described above, the release member 638 is displaced such that thebase plate 654 thereof is snugly received by the cap 614 such that theguide cylinder 650 is aligned with the axis x. At this point, theintermediate flange 648 will rest on the support surfaces 662 on thesupport posts 652. The trigger spring 636 is then placed over the outletmember 626 such that spring 636 is supported at its lower end by theintermediate plate 648. The trigger member 634 is then placed over theoutlet member 626 such that the trigger spring 636 is arranged betweenthe trigger plate 646 and the intermediate plate 648. Importantly, thetrigger fingers 642 must be aligned with the support posts 652 and therelease finger 644 must be aligned with the release posts 653.

The first bearing surface 666 defines a hole in the trigger plate 646through which the outlet member 626 passes. In addition, the firstbearing surface 666 engages the guide member 626 and the second bearingsurfaces 668 on the guide fingers 640 engage the intermediate flange 648such that the trigger member 634 also can move only along thelongitudinal axis x.

The actuator return spring 628 is then placed around the trigger member634 until it rests on the base plate 654 of the release member 638. Theoutlet member 624 is then placed over the trigger member 634 such thatthe actuator cylinder 670 engages the guide cylinder 650 such that theactuator member 624 moves only along the system axis x. In thisconfiguration, the actuator return spring 628 opposes downward motion ofthe actuator member 624 as generally discussed above.

The purpose of the metering assembly 610 is generally to allow the userto pull down on the actuator member 624 and initiate a sequence ofevents that open and close the valve assembly 606 substantiallyindependent from the actions of the user. In particular, in the ninthand tenth embodiments it would be possible for the user to pull down onthe actuator member halfway and place the valve assembly in a state inwhich texture material may freely flow out of the container assembly. Inthose ninth and tenth embodiments, the valve assembly will automaticallybe closed only if the user pulls the actuator member down past apredetermined point.

In this eleventh embodiment described in FIGS. 34-37, the triggerassembly 630 controls the opening of the valve assembly 606 while therelease assembly 632 controls the closing of the valve assembly 606. Theuser merely energizes the metering assembly 610 by compressing varioussprings and then triggers the automatic sequence of events that opensand closes the valve assembly 606. The user is thus prevent from placingthe valve assembly 606 in an intermediate configuration in which texturematerial is allowed to freely flow from inside the container assembly604.

The sequence of events initiated by the user's pulling of the actuatormember 624 will now be described with reference to FIGS. 34A-G and35A-G.

In FIGS. 34A and 35A, the mechanical portion 602 is shown in itspredispensing state in which the actuator member 624 is in its uppermostposition and the valve assembly 606 is closed. The user then applies adownward force on the actuator member 624 as shown by arrows in FIGS.34B and 35B. As shown best in FIG. 35B, the actuator surface 656 engagesthe trigger member 634 such that the trigger member 634 moves down withthe actuator member 624. The mechanical portion 602 is in apretriggering state in FIGS. 34B and 35B in which the actuator returnspring 628 and trigger spring 636 are both compressed. At this point,the valve spring 620 is not compressed and the valve assembly 606 isstill in its closed configuration. Then, as shown in FIGS. 34C and 35C,the trigger surfaces 658 on the trigger fingers 642 engage the releasesurfaces 664 on the support posts 652. The trigger fingers 642 aresupported by the intermediate plate 648 at this point, so theinteraction of the trigger surfaces 658 with the release surfaces 664causes the support posts 652 to deflect slightly away from the systemaxis x. The situation depicted in FIGS. 34C and 35C will be referred toas the triggering state.

Referring now to FIGS. 34D and 35D, when the support posts 652 deflectfar enough outward, the support surface 662 is removed from underneaththe intermediate flange 648. At this point, the trigger spring 636,which is fully compressed in the pretriggering state, and which also isstronger than the valve spring 620, expands, forcing the intermediateplate 648 downward and compressing the valve spring 620. This state isshown in FIGS. 34D and 35D and will be referred to as the open state.

In this open state, the valve assembly has been placed in its openconfiguration, and fluid is free to flow into a stem inlet 672 andthrough a stem passageway 674 formed in the valve stem 618. Fluid thenflows into an outlet chamber 676 formed in the outlet member 626 andsubsequently out of the mechanical portion 602. A dispensing path DP isthus formed.

Referring now to FIG. 35D, it can be seen that the release posts 653begin to engage the cam surfaces 660 when the mechanical portion 602 isin this open state.

When the trigger spring 636 forces the intermediate flange 648 downwardto open the valve assembly 606, resistance to downward movement of theactuator member 624 is substantially decreased. Accordingly, the userwho is applying a downward force on the actuator member will quicklymove the actuator member into the position shown in FIGS. 34E and 35E.The state shown in FIGS. 34E and 35E will be referred to as the releasestate. In this release state, the release posts 653 have acted on thecam surfaces 660 to deflect the release fingers 644 inwardly towards thesystem axis x. The actuator surface 656 no longer engages the triggermember 634. At this point, the valve spring 620 is fully compressed andwill exert a fairly strong upward force on the valve stem 618. Becausethe trigger member 634 has been released from the actuator surface 656,nothing opposes upward motion of the valve stem 618. Accordingly, thevalve spring 620 forces the valve stem 618, and thus the intermediateflange 648 upward until the valve stem again engages the valve seal 622to place the valve assembly 606 in its closed configuration. This isshown in FIGS. 34F and 35F and will be referred to as the releasedstate.

As the intermediate flange 648 moves up with the valve stem 618, it willforce the trigger member 634 up through the trigger spring 620.

The operator then releases the actuator member 624. As described above,the downward motion of the actuator member 624 has compressed theactuator return spring 628, so, when the actuator member 624 isreleased, the actuator return spring 628 forces the actuator member backup to its uppermost position as shown in FIGS. 34G and 35G. At thispoint, the release fingers 644 are free to spring back into theirnondeformed state as perhaps best shown in FIG. 35G. And as shown inFIG. 34G, the support posts 652 spring back to their originalconfiguration with the support surfaces 62 again supporting theintermediate flange 648. The mechanical assembly 602 thus returns to itspredispensing state as shown in FIGS. 34A and 35A. As described above,the user need only energize this system by compressing various springsand trigger the system by moving the actuator member 624 passed apredetermined point. Once these actions have taken place, the meteringassembly 610 automatically opens and closes the valve assembly 606 suchthat only a predetermined amount of texture material is allowed to flowout along the dispensing path DP. Again, the amount of texture materialreleased during the short period of time that the valve assembly isopened is determined by various factors such as the initial pressure ofthe propellant material, and volume of the propellant material, theamount that the valve stem moves when it is placed into its openposition, the sizes of the various orifices and restrictions involved informing the dispensing path DP, the relative sizes of the trigger spring636 and the valve spring 620, and the exact physical locations of theactuator surface 656, trigger 658, cam surface 660, support surface 662,release surface 664, and release post 653.

XV. Twelfth Embodiment

Referring now to FIG. 38, depicted at 700 therein is a twelfthembodiment of a dispensing system constructed in accordance with, andembodying, the principles of the present invention. This twelfthembodiment includes a fluid portion as described above and a mechanicalportion 702 for dispensing acoustic texture material forming part of thefluid portion.

The mechanical portion 702 comprises a container assembly 704, a valveassembly 706, an actuator assembly 708, and a metering member 710.

The container assembly 704 comprises a container 712 and a cap 714. Thevalve assembly 706 comprises a valve housing 716, a valve stem 718, avalve spring 720, and a valve seal 722.

The cap 714 and valve housing 716 are attached to the container 712. Thevalve seal 722 is mounted to the cap 714, and the valve stem 718 passesthrough the valve seal 722. The valve spring 720 is arranged between thecap 714 and the valve stem 718 to bias the valve stem 718 upward suchthat the valve assembly 706 is normally in a closed configuration.

The actuator assembly 708 comprises an outlet cap 726 and an actuatormember 728. The actuator member 728 is rigidly connected to the valvestem 718, and the outlet cap 726 is rigidly connected to the actuatormember 728.

The metering member 710 is rigidly connected to the cap 714 around thevalve stem 718 immediately below the actuator member 728.

A stop surface 730 is formed on a bottom portion of the actuator member728. A limiting surface 732 is formed on an upper portion of themetering member 710. The stop surface 730 and limiting surface 732 bothhave a generally frustoconical shape. In the exemplary mechanicalportion 702, the surfaces 730 and 732 match each other.

The valve housing 716 defines a valve chamber 734 within the container704. As with the embodiments discussed above, a pick-up tube is used toallow fluid communication between a bottom portion of the container 704and the valve chamber 734. The pressurized propellant materialaccumulates at the top of the container 704 and forces acoustic texturematerial at the bottom of the container 704 through the pick-up tube andinto the valve chamber 734. Accordingly, pressurized acoustic texturematerial is present in the valve chamber 734.

In use, the actuator member 728 is depressed downward against the forceof the valve spring 720 such that the valve stem 734 disengages from thevalve seal 722 and creates a dispensing path through which texturematerial may exit the mechanical portion 702. In particular, when thevalve stem 718 disengages from the valve seal 722, texture materialwithin the valve chamber 734 flows into a stem inlet 736 and a stempassageway 738 in the valve stem 718. The texture material then flowsthrough an outlet chamber 740 defined by the actuator member 728 andoutlet cap 726. Finally, the acoustic texture material exits through anoutlet opening 742 formed in the outlet cap 726.

The metering member 710 performs two basic functions. First, the stopsurface 730 on the actuator member 728 engages the limiting surface 732on the metering member 710 to limit the distance the valve stem 718travels relative to the valve seal 722. This effectively restricts thesize of the opening through which the texture material must pass as itexits the mechanical portion 702 and thus assists the user incontrolling the amount of texture material released.

The interaction of the stop surface 730 with the limiting surface 732also prevents cocking of the valve stem 718 relative to the longitudinalaxis of the container 712. This aids the user in aiming the device whiledispensing the texture material.

The metering member 710 thus assists the user in operating the valveassembly 706 in a manner that allows the texture material to be appliedproperly.

XVI. Thirteenth Embodiment

Referring now to FIG. 39, depicted at 750 therein is a thirteenthembodiment of the dispensing system constructed in accordance with, andembodying, the principles of the present invention. The dispensingsystem 750 comprises a fluid portion 752 and a mechanical portion 754.

In the dispensing system 750, the fluid portion 752 is initially storedat two locations as indicated by the suffix a and b. The texturematerial to be dispensed is shown at 756 along with air at ambientpressures as indicated at 758. Pressurized propellant material is storedas shown by the reference character 760.

The mechanical portion 754 comprises a hopper assembly 762 and apropellant assembly 764.

The hopper assembly 762 comprises a hopper container 766 and a hopperseal 768. The propellant assembly 764 comprises a propellant container770, a propellant nozzle 772, and an actuator button 774.

The propellant assembly 764 is conventional and is adapted to contain apressurized, gaseous fluid such as air or nitrogen. Similar assembliesare used to dispense inert gases such as air and nitrogen for thepurpose of cleaning. For example, a number of products on the marketallow computer and electronics equipment to be cleaned using a stream ofinert gas contained in assemblies such as the propellant assembly 764.The propellant assembly 764 is operated by depressing the actuatorbutton 774, which opens an internal valve (not shown) and allows thepressurized inert fluid to flow from the propellant container 770 to thepropellant nozzle 772.

The hopper container 766 comprises a hopper portion 776 and an outletportion 778. The hopper portion defines a hopper chamber 780. The outletportion 778 defines an outlet chamber 782, a portion of which isidentified by reference characters 784 as a mixing area. The mixing areais immediately adjacent to an outlet opening 786 formed in the outletportion 778.

In use, the propellant nozzle 772 extends from the propellant container770. The outlet portion 778 of the propellant container 770 contains asubstantial portion of the propellant nozzle 772. The propellant nozzle772 defines a nozzle passageway 788 that terminates in a nozzle opening790. When assembled, the nozzle opening 790 is located adjacent to theoutlet opening 786, with the mixing area 784 arranged between the nozzleopening 790 and the outlet opening 786. The hopper seal 768 seals thehopper portion 778 of the hopper container 776 against the outer surfaceof the propellant nozzle 772.

The hopper container 776 contains the acoustic texture material 756 andthe ambient air 758. The propellant assembly 764 contains the propellantmaterial 760.

In use, the hopper assembly 762 is arranged such that the hopper portion760 is above the outlet portion 778. This allows gravity to feed thetexture material 756 into the outlet chamber 782. Texture material inthe outlet chamber 782 flows into the mixing area. When the actuatorbutton 774 is depressed, a stream of pressurized propellant materialflows through the nozzle passageway 788 and out of the nozzle openings790 where it mixes with the texture material in the mixing area 784 andsubsequently carries a portion of the texture material out of the outletopening 786.

The propellant assembly 764 further comprises an outlet cap 792 fromwhich the propellant nozzle 772 extends. It would be possible toincorporate the functions of the propellant nozzle 772 and the outletportion 778 of the hopper container 766 into the outlet cap 792.

XVII. Fourteenth Embodiment

Referring now to FIGS. 40-42, depicted therein at 800 is a fourteenthembodiment of the dispensing system constructed in accordance with, andembodying, the principles of the present invention. The dispensingsystem 800 comprises a mechanical portion 802 and a fluid portion asdiscussed above.

The mechanical portion 802 comprises a container assembly 804, a valveassembly 806, an outlet assembly 808, and a metering assembly 810.

The container assembly 804 comprises a container 812 on which issealingly mounted a cap 814.

The valve assembly 806 comprises a valve housing 816, a valve stem 818,a valve spring 820, and a valve seal 822. As in the ninth throughtwelfth embodiments discussed above, the valve housing 816 is mountedwithin the container 812 and pressurized acoustic texture material islocated within the valve housing 816. The valve seal 822 is mounted ontothe cap 814 and in turn mounts the valve stem 818 to the cap 814 in amanner that allows the stem 818 to move up and down relative to thecontainer 812. The valve spring 820 resists downward movement of thevalve stem 818.

The valve assembly 806 is shown in its closed configuration in FIG. 40,and pressurized texture material is not allowed to flow out of themechanical portion 802.

The outlet assembly 808 comprises an outlet member fixedly attached tothe valve stem 818, and a valve cap 826.

The metering assembly 808 comprises a torsion member 828 and a basemember 830. The torsion member comprises a torsion bar portion 832,actuator fingers 834, and trigger projections 836. The base member 830comprises a mounting flange 838 and bar supports 840.

The base member 830 is assembled on to the cap 814 using the mountingflange 838. The base member 830 is thus secured relative to thecontainer 812. The bar supports 840 extend upwardly and support bothends of the torsion bar portion 832 of the torsion member 828.

The base member 830 further defines a trigger surface 842 and first andsecond release surfaces 844 (FIG. 42). In addition, trigger ledges 846are formed on either side of the outlet member 824 as perhaps best shownin FIG. 41. In addition, release edges 848 are formed on the triggerprojections 836. A trigger surface 849 (FIG. 40) is formed on theactuator fingers 834.

When the mechanical portion 802 is in its predispensing state as shownin FIG. 40, the actuator fingers 834 are canted upwardly and the triggerprojections 836 rest on the release ledges 846 and trigger surface 842.Pushing downward on the actuator fingers 834 as shown by the arrow inFIG. 40 displaces the actuator fingers 834 downward. Because the triggerprojections 836 are supported by the trigger surface 842, the triggerprojections 836 initially cannot move. This creates torsion in thetorsion bar portion 832 of the torsion member 828. As the actuatorfingers 834 move down further, the trigger surfaces 849 act on the basemember 830 and displace the trigger surface away from the torsion barportion 832 until at some point the trigger surface 842 no longersupports the trigger projections 836. At this point, the torsion builtup in the torsion bar portion 832 causes the trigger projections 836 tosnap downwardly. Because these trigger projections 836 rest on thetrigger ledges 846, the downward movement of the trigger projections 836is transferred to the outlet member 824 and thus the valve stem 818. Asthe valve stem 818 moves downward, it disengages from the valve seal 822and allows texture material to flow out of the mechanical portion 802.

As the trigger projections descend, the release edges 848 thereon engagethe release surfaces 844 formed on the base member 830. These releasesurfaces 844 are slanted in a manner that causes the trigger projectionsto separate from each other as they move down after contacting therelease surfaces 844.

As the trigger projections separate from each other, they disengage fromthe trigger ledges 846 formed on the outlet member 824 such that thetrigger projections no longer hold the valve stem 818 down against thevalve spring 820. The valve spring 820 is thus free to return the valvestem 818 back to its original position in which the valve assembly 806is closed. The user then simply releases the actuator fingers 834, andthe torsion bar portion 832 of the torsion member 824 snaps the actuatorfingers 834 and trigger projections 836 back up to the original positionas shown in FIG. 40.

The dispensing system 800 thus allows the user to determine when aportion of acoustic texture material is released from the mechanicalportion 802, but the metering assembly 810 opens and closes the valveassembly 806 in a predetermined sequence that determines the amount oftexture material that is released. Again, the exact amount of texturematerial that is released depends on a number of factors that may beadjusted given the circumstances.

XVIII. Fifteenth Embodiment

Referring now to FIGS. 43-45, depicted therein at 850 is a fifteenthembodiment of a dispensing system constructed in accordance with, andembodying, the principles of the present invention. The dispensingsystem 850 comprises a fluid portion as generally described above withreference to FIG. 1 and a mechanical portion 852. The mechanical portion852 comprises a container assembly 854, a valve assembly 856, an outletassembly 858, and a metering assembly 860.

The valve assembly 856 comprises a valve stem 862, a valve seal 864, anda valve spring 856. The valve assembly 856 works in the same basicmanner as the valve assemblies as a number of other embodimentsdisclosed herein and will not be described in detail.

The outlet assembly 858 comprises an outlet member 868 and is alsoconstructed and operates in the same manner as various outlet assembliesdescribed above.

The metering assembly 860 comprises a base member 870, a gear member872, and a yoke member 874.

The base member 870 comprises a mounting flange 878 that allows the basemember to be adapted onto the container assembly 854. The base member870 further comprises gear supports 880 and actuator supports 882. Thegear members 872 comprise gear portions 884, a yoke housing 886, and anaxle portion 888. The axle portion 888 engages the gear supports 880such that the gear members 872 are mounted on either side of the outletmember 868 with the yoke housing 886 facing in and the gear portions 884facing out.

The actuator member 876 comprises a pair of actuator racks 890 and apair of finger projections 892. The actuator member is mounted on theactuator supports 882 such that the actuator racks 890 are aligned withthe gear portions 884. The finger projections 892 extend on either sideof the outlet member 868 on the opposite side of the actuator supports882.

During use, the user presses downward on the finger projections 892 suchthat teeth 890 a on the actuator rack 890 engage teeth 884 a on the gearportion 884. Accordingly, pushing down on the finger projections 892causes the teeth 890 a and 884 a to engage each other such that the gearportions 884 rotate about a trigger axis 896.

As the gear portions 884 rotate, the housing portions 886 also rotate.These yoke housings define yoke channels 894 that receive either end ofthe yoke member 874. Yoke member 874 is in turn connected to the outletmember 868 such that downward movement of the yoke member 874 istransmitted to the outlet member 868. The outlet member 868 is in turnrigidly connected to the valve stem 862. Accordingly, pushing down onthe finger projections 892 places the valve assembly 856 in its openposition and allows texture material to be dispensed through the outletmember 868.

The gear member 872 is operatively connected to a spring (not shown)which, when the teeth 890 a on the actuator rack 890 rotate the gearmember 884 90 degrees, rotates the gear member 884 an additional 90degrees such that a second set of teeth 884 b on the gear portion 884engage the teeth 890 a on the rack 890. The spring then resets itself tobe ready for the next cycle.

As the yoke housing 886 rotates through the initial 90 degrees, itdrives the yoke member 874 such that the yoke member opens the valveassembly 856. As the yoke housing 886 moves from 90 degrees to 180degrees, it allows the valve spring 866 to force the valve stem 862 backup, thereby closing the valve assembly 856.

The metering assembly 860 thus opens and closes the valve assembly 856in response to pressing of the finger projections 892 to allow apredetermined, limited, amount of acoustic texture material to bereleased from the system 850.

XIX. Sixteenth Embodiment

Referring now to FIGS. 46-48, depicted therein at 900 is a sixteenthembodiment of a dispensing system constructed in accordance with, andembodying, the principles of the present invention. The dispensingsystem 900 comprises a fluid portion as described above with referenceto FIG. 1 and a mechanical portion 902.

The mechanical portion 902 comprises a container assembly 904, a valveassembly 906, an outlet assembly 908, and a metering assembly 910. Thevalve assembly 906 comprises a valve stem 912 and a valve spring 914 andoperates in the same manner as the valve assemblies of a number of otherembodiments described above. The outlet assembly 908 comprises an outletmember 916 that similarly operates in the same basic fashion as theoutlet assemblies described above.

The metering assembly 910 comprises a base member 918, a first gearmember 920, a second gear member 922, a third gear member 924, a fourthgear member 926, a first drive axle 928, a second drive axle 930, afirst drive projection 932 (FIG. 48), a second drive projection 934(FIG. 48), and an actuator member 936. The actuator member 936 issimilar to the actuator member of the fifteenth embodiment describedabove and will not be discussed below in further detail. The first gearmember 920 comprises an outer gear portion 938 and an inner gear portion904. A pair of drive tabs 942 (FIG. 48) extend from either side of theoutlet member 916.

The base member 918 comprises a mounting flange 940 that allows the basemember to be securely mounted onto the container assembly 904. Extendingfrom the mounting flange are first, second, and third gear posts 946,948, and 950. In addition, drive posts 952 extend upwardly from the basemember 918.

The first gear posts 946 support the first gear member 920. The secondgear posts support the second and third gear members 922 and 924. Thethird gear post 950 supports the fourth gear members 926. The driveposts 952 support the first and second drive axles 928 and 930.

Actuator racks 954 extending from the actuator member 936 are alignedwith the outer gear portions 938 of the first gear members 920.Accordingly, pivoting the actuator member 936 about an actuator axis 954causes rotation of the first gear member 920. The inner gear portion 940in turn rotates and engages the second and fourth gear members 922 and926 to cause these to rotate in the same direction. The second gearmember in turn engages the third gear member 924 so that the third andfourth gear members rotate in opposite directions.

As shown in FIG. 46, the first and second drive projections 932 and 934are mounted on the drive axles 928 and 930 such that rotation of thedrive axles 928 and 930 causes the drive projections 932 and 934 to acton the drive tabs 942 and thus place the valve assembly in its openconfiguration. When the drive projections 932 and 934 rotate slightlyless than 90 degrees, they disengage from the drive tabs 942 and allowthe valve spring 914 to raise the valve stem 912 and place the valveassembly 906 back into its closed position. The drive projections 932and 934 are then rotated approximately 270 degrees until they again comeinto contact with the drive tabs 942. The process may be repeated.Again, the metering assembly 910 opens and closes the valve assembly 906in a manner that dispenses a limited, controlled amount of texturematerial and does not allow the user to leave the valve assembly 906 inits open configuration for an extended period of time.

It is apparent that various modifications could be made the presentinvention without departing from the basic teachings thereof.

1. An outlet system for a hardenable acoustic texture material aerosoldispensing system comprising a discharge assembly movably supported suchthat a first return member automatically returns the discharge assemblyto a first position when the discharge assembly is displaced apredetermined distance from the first position.
 2. The outlet system asrecited in claim 1, further comprising a release member detachablyattached to the discharge assembly as the discharge assembly moves thepredetermined distance, where the release member is detached from thedischarge assembly when the discharge assembly begins to return to thefirst position.
 3. The outlet system as recited in claim 2, furthercomprising a second return member for displacing the release member todetachably attach the release member to the discharge assembly after thedischarge assembly returns to the first position.
 4. The outlet systemas recited in claim 1, further comprising a first biasing memberarranged automatically to displace the discharge assembly at least aportion of the first predetermined distance from the first position. 5.The outlet system as recited in claim 1, further comprising a levermember for facilitating displacement of the displacement of thedischarge assembly the predetermined distance from the first position,where the lever member is released from the discharge assembly after thedischarge assembly moves the predetermined distance.